SAFETY PRECAUTIONS
If special testing equipment is required during a road test, note the following
Scheme 11
| WARNING | Improperly secured testing and measuring equipment and distraction during a road test increase the risk of an accident. The passenger airbag could pose a risk if it deploys in a collision. Operating testing equipment while driving causes it to shift position. There is an increased risk of injury due to unsecured testing equipment. Move the front passenger seat as far back as possible. Do NOT use the following vehicle diagnosis testers: VAS 5051 --, VAS 5051A and VAS 5051B --. Testing and measuring instruments -1- must lay flat on the passenger's thighs and be operated by him or her, as shown in the illustration. |
| CAUTION | Danger of causing damage to other electronic components when disconnecting the battery. Complete the steps for disconnecting the battery. |
Disconnect the battery. Refer to [For transmission(s) 02E] Removal and Installation .
To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following
- Do not touch or remove ignition wires when engine is running or turning at starter speed.
- Always turn the ignition off before disconnecting or reconnecting wires for the ignition system, including high voltage wiring and test leads.
- If the engine is to be cranked at starting RPM without starting, disconnect the connectors from the ignition coils and fuel injectors.
- Cleaning the engine should only be performed with ignition turned off.
IGNITION SYSTEM
- The Engine Control Module (ECM) is equipped with On Board Diagnostics (OBD).
- For the electric components to work properly, a voltage of at least 11.5 Volts is required.
- It is possible that the control module will recognize a malfunction and store a Diagnostic Trouble Code (DTC) during some tests. After completing all checks and repairs, check the DTC memory and erase the memory, if necessary.
- If the engine only starts briefly and then turns off again after troubleshooting, repair or checking of the components, it may be that the immobilizer is blocking the ECM. DTC memory must then be checked and if necessary, control module must be adapted.
Scheme 12
- Knock Sensor (KS) 1 -G61- Contacts gold plated
- Knock Sensor (KS) 2 -G66- Contacts gold plated
- Ignition Coil with Power Output Stage -(N70, N127, N291, N292)- Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(ref-505690-S04111672332012100100000) To remove, use the ignition coil puller T40039.
- Spark Plug 30 Nm To remove, use the spark plug removal tool 3122 B Removing and installing, refer to the Maintenance Procedures
- Bolt 20 Nm Tightening specifications affect the function of the knock sensor
- Bolt 10 Nm
- Camshaft Position (CMP) Sensor -G40- Contacts gold plated
- O-ring If damaged, replace O-ring
IGNITION COILS WITH POWER OUTPUT STAGES
Special tools and workshop equipment required
- Ignition Coil Puller T40039
Removing
Remove engine cover.
Open both bolts on the connector strip.
Pull all the ignition coils out approximately 30 mm from the spark plug holes using the T40039.
Scheme 13
The following step applies only to the engine code CETA.
Disconnect the connectors -5 through 12- on the all cam adjustment actuators.
Scheme 14
Release the connectors and pull all connectors simultaneously off from the ignition coils.
Scheme 15
Installing
Insert all ignition coils loosely into each spark plug shaft.
Align the ignition coils to the connectors and then connect all of the connectors simultaneously onto the ignition coils.
Press the ignition coils uniformly onto the spark plugs by hand (do not use any impact tools).
Knock Sensor 1 -G61
Removing
Remove the electrical connector -2- from the Knock Sensor (KS) 1.
Scheme 16
Remove the coolant pump with the coolant thermostat. Refer to Removal and Installation .
Note. The KS 1 is located below the intake manifold behind the coolant pump.
Remove the KS 1.
Installing
Install in reverse order of removal.
- Tightening specifications: Ignition system assembly overview, refer to «IGNITION SYSTEM OVERVIEW»(ref-505690-S02011424292012100100000)
Engine Speed Sensor -G28
Special tools and workshop equipment required
- Socket 4 mm T10370
- Assembly Tool T10118
Removing
Remove the engine cover.
Remove the cover for the air guide; disengage the side clips to do this -arrows-.
Scheme 17
Remove the air guide pipe -1-.
Scheme 18
Note. The air guide -2- does not have to be removed.
Open the air guide pipe hose clamp -2-.
Scheme 19
Disconnect the electrical harness connector -arrow-.
Remove the noise insulation. Refer to Removal and Installation .
Remove the bolt -1 and 4- and remove the air guide hose downward from the throttle valve control module -J338-.
Remove the air guide hose -1- from the charge air cooler and remove the air guide pipe downward.
Scheme 20
Disconnect electrical connector -1- on Engine Speed (RPM) sensor.
Scheme 21
Remove the RPM sensor bolt.
Installing
Install in reverse order of removal. Note the following
- Tightening specifications: Component locations overview, refer to «COMPONENT LOCATIONS OVERVIEW»(ref-505666-S05296268252012100100000)